Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE SERVICE PLUG GRIP
4. REMOVE REAR SEAT CUSHION ASSEMBLY
5. REMOVE ROOM NO. 3 PARTITION PAD
a. Remove the clip and room partition pad.
6. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the 2 connectors.
7. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Disconnect the fuel main tubes and fuel return vent tube.
1. Remove the 2 tube joint clips and fuel tubes.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
b. Remove the 8 bolts and set plate.
c. Disconnect the fuel tube.
d. Remove the fuel suction tube with pump and gauge from the fuel tank.
NOTE:
- Make sure that the sender gauge arm does not bend.
- Do not damage the fuel suction tube with pump and gauge.
8. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
9. REMOVE FUEL SENDER GAUGE ASSEMBLY
a. Remove the 5 screws and fuel sender gauge.
10. REMOVE EXHAUST PIPE ASSEMBLY
a. Remove the exhaust pipe.
11. REMOVE FRONT FLOOR COVER CENTER RH
a. Remove the 3 nuts, 2 clips and floor cover.
12. REMOVE FRONT FLOOR COVER CENTER LH
a. Remove the 3 nuts, 2 clips and floor cover.
13. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR
a. Remove the 5 nuts and heat insulator.
14. REMOVE OUTSIDE AIR GUIDE PLATE RH
a. Remove the 4 nuts and plate.
15. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
16. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 2 nuts and differential support protector.
17. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
a. Remove the 2 nuts and differential support protector.
18. REMOVE REAR FLOOR SIDE MEMBER COVER LH
a. Remove the 3 bolts and member cover.
19. REMOVE REAR FLOOR SIDE MEMBER COVER RH
a. Remove the 3 bolts and member cover.
20. REMOVE REAR SUSPENSION MEMBER BRACE LH
a. Remove the 4 bolts and suspension member brace.
21. REMOVE REAR SUSPENSION MEMBER BRACE RH
a. Remove the 4 bolts and suspension member brace.
22. DISCONNECT PARKING BRAKE CABLE ASSEMBLY
a. Detach the 2 parking brake cables from the 4 clamps.
b. Remove the 4 bolts and disconnect the 2 parking brake cables from the parking brake equalizer.
23. DISCONNECT FUEL TANK RETURN VENT TUBE
a. Disconnect the fuel tank return vent tube.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
24. DISCONNECT FUEL TANK MAIN TUBE SUBASSEMBLY
a. Disconnect the fuel tank main tube RH.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not forcefully bend or twist the nylon tube.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
b. Disconnect the fuel tank main tube LH.
NOTE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not forcefully bend or twist the nylon tube.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
25. DISCONNECT FUEL TANK VENT HOSE SUBASSEMBLY
a. Remove the clamp and disconnect the vent hose.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
26. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
a. Remove the fuel tube clamp and disconnect the canister tube.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering with a plastic bag and tape after disconnecting the fuel tubes.
27. DISCONNECT FUEL TANK WIRE
a. Disconnect the fuel vapor containment valve connector and 2 clamps.
28. REMOVE FUEL TANK SUB-ASSEMBLY
a. Loosen the 2 fuel filler pipe bolts.
b. Place a mission jack under the fuel tank.
c. Remove the 4 bolts and 2 fuel tank bands.
d. Slowly lower the mission jack slightly.
NOTE: Make sure that no load is applied to the fuel filler pipe.
e. Remove the clamp, disconnect the fuel filler pipe from the fuel tank, and lower the mission jack.
29. REMOVE NO. 3 FUEL TANK PROTECTOR
30. REMOVE FUEL PRESSURE SENSOR
31. REMOVE FUEL TANK VENT TUBE SET PLATE
32. REMOVE FUEL TANK WIRE
a. Remove the 7 clamps and tank wire from the tank.
33. REMOVE FUEL TANK TO CANISTER TUBE SUBASSEMBLY
a. Remove the 4 screws, gasket and canister tube.
34. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Remove the clamp, fuel tank main tube and return tube.
b. Detach the 2 claws and remove the edge protector.
35. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Remove the vent hose from the fuel tank.
NOTE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
36. REMOVE FUEL TANK CUSHION
a. Remove the 11 tank cushions.
b. Remove the tank protector and tank cushion.
INSTALLATION
1. INSTALL FUEL TANK CUSHION
a. Install the tank cushion and tank protector.
b. Install the 11 tank cushions.
2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Install the vent hose to the fuel tank.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Attach the 2 claws to the claw holes and install a new edge protector.
b. Install the clamp, fuel tank main tube and return tube.
4. INSTALL FUEL TANK TO CANISTER TUBE SUBASSEMBLY
a. Install a new gasket and the canister tube with the 4 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
5. INSTALL FUEL TANK WIRE
a. Install the tank wire with the 7 clamps.
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. INSTALL FUEL TANK PRESSURE SENSOR
8. INSTALL NO. 3 FUEL TANK PROTECTOR
9. INSTALL FUEL TANK SUB-ASSEMBLY
a. Set the fuel tank on a mission jack and raise the fuel tank.
b. Install the clamp, and connect the fuel filler pipe to the fuel tank.
NOTE:
- Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
- Do not twist or forcefully insert the filler pipe.
- After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time ,securely insert the clamp into the slit.
c. Raise the mission jack.
d. Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Tighten the 2 fuel filler pipe bolts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
10. CONNECT FUEL TANK WIRE
a. Connect the fuel vapor containment valve connector and 2 clamps.
11. CONNECT FUEL TANK TO CANISTER TUBE SUBASSEMBLY
a. Connect the canister tube and install the clamp.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
12. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
a. Connect the fuel tank vent hose and install the clamp.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
a. Connect the fuel tank main tube (LH).
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
b. Connect the fuel tank main tube (RH).
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
14. CONNECT FUEL TANK RETURN VENT TUBE
a. Connect the fuel return vent tube and install the retainer.
HINT: Push the parts together firmly until a "click" sound is heard.
NOTE:
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
15. CONNECT PARKING BRAKE CABLE ASSEMBLY
a. Connect the 2 parking brake cables to the parking brake equalizer.
b. Install the 2 parking brake cables with the 4 bolts.
Torque:
6.0 N.m (61 kgf.cm, 53 in.lbf) for bolt A
19 N.m (193 kgf.cm, 14 ft.lbf) for bolt B
c. Attach the 2 parking brake cables to the 4 clamps.
16. INSTALL REAR SUSPENSION MEMBER BRACE RH
a. Install the suspension member brace with the 4 bolts.
Torque: 19 N.m (193 kgf.cm, 14 ft.lbf)
17. INSTALL REAR SUSPENSION MEMBER BRACE LH
a. Install the suspension member brace with the 4 bolts.
Torque: 19 N.m (193 kgf.cm, 14 ft.lbf)
18. INSTALL REAR FLOOR SIDE MEMBER COVER LH
a. Install the member cover with the 3 bolts.
19. INSTALL REAR FLOOR SIDE MEMBER COVER RH
a. Install the member cover with the 3 bolts.
20. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential supporter with the 2 nuts.
21. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
a. Install the differential supporter with the 2 nuts.
22. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
23. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY
24. ADJUST NO. 2 AND NO. 3 JOINT ANGLE
25. INSTALL OUTSIDE AIR GUIDE PLATE RH
a. Install the plate with the 4 nuts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
26. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
a. Install the heat insulator with the 5 nuts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
27. INSTALL FRONT FLOOR COVER CENTER LH
a. Install the floor cover center with the 3 nuts.
28. INSTALL FRONT FLOOR COVER CENTER RH
a. Install the floor cover center with the 3 nuts.
29. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe.
30. INSTALL FUEL SENDER GAUGE ASSEMBLY
a. Install the sender gauge with the 5 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
31. INSTALL REAR FLOOR SERVICE HOLE COVER
a. Connect the fuel sender gauge connector.
b. Install the service hole cover with new butyl tape.
32. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
a. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
b. Connect the fuel hose, and set the fuel suction with pump and gauge.
NOTE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel hose, do not forcibly pull the hose.
c. Install the set plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
HINT: Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.
d. Install the 2 fuel tank tubes with the 2 tube joint clips.
NOTE:
- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clips are on the collars of the fuel tube joints.
- After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
33. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
a. Connect the 2 connectors.
b. Install the service hole cover with new butyl tape.
34. INSTALL ROOM NO. 3 PARTITION PAD
a. Install the partition pad with the clip.
35. INSTALL REAR SEAT CUSHION ASSEMBLY
36. INSTALL SERVICE PLUG GRIP
37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
38. CHECK FOR FUEL LEAKS
39. PERFORM INITIALIZATION
a. Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.